Report 36 d,e,f,s,i.qxd:Report - KBA

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Comparable press 3,597 Sheetfed Offset | Cost efficiency Cheaper kit can prove expensive Productivity – a key cost factor A lot of printers are hoping to survive the current crisis by clinging to outdated kit and economising on maintenance and service. Others are pursuing a policy of counter-cyclical investment to hone their competitiveness in an ever harsher market climate in preparation for an eventual upturn. When investing in a new press, decision-makers often place far too much emphasis on price. As the following calculations taken from large-format packaging printing illustrate, economising in the wrong place can prove expensive: initial capital savings, for example, may later be outweighed by costs further down the line, in production. PileTronic automated logistics workflow 1 Pile turner with pallet dispenser 2 Pile conveyor to the relevant feeders 3 Automated DriveTronic feeder with nonstop facility When printing packaging on an industrial scale two basic aims are to maximise output while minimising changeover times. Where the substrates used are identical, the key parameters influencing a press line’s economic efficiency and total production costs are net productivity in conjunction with the labour and energy input required for the various jobs. It there- Annual production output in jobs 8 Report 36 | 2010 4 Park positions for prepared piles 5 Automatic turner for empty pallets 6 Automated nonstop delivery 7 Park positions for printed piles fore follows that extensive automation may well justify the higher capital investment cost. Do not compare apples with pears In our examples we employed a classic calculation of machine overheads (see chart on opposite page) to compare the productivity and cost efficiency of a highly auto- KBA Rapida 142-6+coater Gain with Rapida 142 5,914 2,316 = 64 % No. of jobs per year Rapida 142, output gain 11,000 95 % 90 % 10,000 85 % 9,000 80 % 75 % 8,000 7,000 70 % 65 % 60 % 6,000 5,000 5,914 jobs 55 % 50 % 45 % 40 % 4,000 35 % 3,000 3,597 jobs 30 % 25 % 2,000 20 % 15 % 1,000 10 % 5 % 0 0 % 1,000 2,000 3,000 4,000 5,000 6,000 7,000 8,000 9,000 10,000 11,000 12,000 13,000 14,000 15,000 Ø run length (sheets) Comparison of makeready times Job changing program Blanket washing Roller washing Impression cylinder washing Ink duct washing Coating change Comparable press = 45 minutes KBA Rapida 142-6+coater = 23 minutes mated Rapida 142 large-format sixcolour coater press (Rapida 142- 6+coater) with automated pile logistics – a constellation commonly used to print packaging – and a less highly automated press from another German manufacturer in the same 1020 x 1420mm (40.15 x 55.9in) format but with no automated pile logistics. The higher capital cost of the Rapida 142-6+ Annual production output in sheets No. of sheets per year 50,000,000 45,000,000 40,000,000 35,000,000 30,000,000 25,000,000 20,000,000 15,000,000 10,000,000 5,000,000 0 5 coater (100%) relative to the other press (85%) was partially attributable to the automated pile-logistics system in which it is embedded. Lower hourly rate despite higher capital cost However, this also (beneficially) influences the hourly rate and the total payback period. Even though the initial capital cost of the com- Comparable press KBA Rapida 142-6+coater Gain with Rapida 142 17,985,000 29,568,000 11,583,000 = 64 % 29,568,000 sheets 17,985,000 sheets Plate change Coating plate change Other makeready First proof Colour measurement/control Final proof Corrections 10 15 20 25 30 35 40 45 Time in minutes Rapida 142, output gain 1,000 2,000 3,000 4,000 5,000 6,000 7,000 8,000 9,000 10,000 11,000 12,000 13,000 14,000 15,000 Ø run length (sheets) 95 % 90 % 85 % 80 % 75 % 70 % 65 % 60 % 55 % 50 % 45 % 40 % 35 % 30 % 25 % 20 % 15 % 10 % 5 % 0 %
€569.03 parable press is 15% lower than for the Rapida 142 with peripherals, its hourly rate is 18% higher. The Rapida’s reduced rate is largely the result of its higher output in tandem with a fully automated, interlinked logistics system. Lower labour costs and much lower energy consumption with KBA’s VariDry dryer also helped trim costs (see article on energy efficiency, pages 22-23). When calculating the respective output levels of the two presses we took as our basis the makeready times and average run length per job. As the top right-hand graph on page 8 illustrates, a complete job change on the Rapida 142 takes just 23 minutes – little more than half the time on the rival press. A major reason for this is the Rapida’s advanced level of automation and simultaneous washing cycles. Higher automation is also the reason why changes of coating, printing plates and coating plates are also much faster on the Rapida. 2,300 more jobs per year Shorter makeready times mean that the Rapida can print a much larger number of jobs per shift or day. Assuming an average run length of 5,000 sheets per job, the 15,000sph Rapida 142’s higher level of automation and modestly higher production speed enable it to print 2,316 more jobs or 11,583,000 more sheets per year than the cheaper rival press. The two graphs at the bottom of page 8 show the output in jobs and sheets respectively on the Rapida Per-job costs Specifications KBA Rapida 142-6+coater Comparable press Plinth ☑ ☑ Automated nonstop feeder ☑ ☑ Automated nonstop delivery ☑ ☑ Interlinked pile logistics ☑ PileTronic ☐ Not interlinked Automatic plate change ☑ FAPC ☐ Semi-automatic Washing system ☑ Blanket/impression cylinders, rollers ☑ Blanket/impression cylinders, rollers Simultaneous washing ☑ CleanTronic Synchro ☐ Not available Automatic coating plate change ☑ ☐ Manual Coating system cleaning ☑ Automatic ☐ Manual Register system ☑ Automatic Camera Register ☐ Not available Energy-efficient dryer ☑ VariDry ☐ Not available Inline colour measurement/control ☑ QualiTronic CC ☑ Online PDF control ☑ DensiTronic PDF ☐ Not available Machine overheads KBA Rapida 142-6+coater Comparable press Working days per year 250 250 Working hours per shift 7.4 7.4 Number of shifts 3 3 Gross capacity utilisation rate 300 % 300 % Net capacity utilisation rate Printing as proportion of 90 % 85 % production output 90 % 85 % Makeready per job 23 minutes 45 minutes Maximum production speed 15,000 sheets/h 14,000 sheets/h Energy-efficient dryer VariDry Not available Average run length 5,000 sheets 5,000 sheets Price of press 100 % 85 % Payback period 37 months 38 months Calculated hourly rate 375 euros 443 euros 142 and the comparable press for average run lengths of between 1,000 and 15,000 sheets. They can be calculated individually for any printing plant. The per-job costs for the two presses depend to a large extent on output. In the graph below it can be seen that, for an assumed average run length of 5,000 sheets, the per- Comparable press KBA Rapida 142-6+coater Gain with Rapida 142 Per-job costs €1,100 €1,000 €900 €800 €700 €600 €500 €400 €300 €200 €100 €309.80 €259.23 Rapida 142, cost gain €0 €0 10,336 8,724 7,531 6,625 5,914 5,340 4,868 4,473 4,137 3,848 3,596 3,376 3,181 3,007 2,852 Jobs / year 1,000 2,000 3,000 4,000 5,000 6,000 7,000 8,000 9,000 10,000 11,000 12,000 13,000 14,000 15,000 Ø run length (sh) €400 €350 €300 €250 €200 €150 €100 €50 job costs with the Rapida 142 are €259.30 lower than with the comparable press. No false economies While there is some truth in the much-repeated argument that a highly productive press is only worth the extra money if it is utilised to the full, it is wrong to conclude that a cheaper, less productive press is the right choice where order volumes leave a lot to be desired. This defensive investment philosophy ignores the significant cost drawback of competing with rivals whose equipment is much more productive. Pre-investment analysis The examples given, based on an average run length of 5,000 sheets, indicate that even if the initial capital cost is higher, it may still be wiser to go for a highly automated press line with correspondingly shorter makeready times. Where run lengths are generally long and there are fewer changes, makeready times necessarily play a minor role. But where short runs dominate the production schedule, and this typically applies to printers of cosmetics and pharmaceutical packaging, they can be a key factor – along with labour costs, energy consumption and waste rates – in determining economic viability. In view of the flexibility demanded today, a press that performs well on every measure may therefore prove to be the better business option. The Rapidas fit the bill. Printers’ job structures differ enormously. When contemplating the purchase of new kit, these differences can be addressed by conducting individual productivity and cost-efficiency analyses. KBA is always happy to help. Jürgen Veil juergen.veil@kba.com Report 36 | 2010 9
Page 1 and 2: 1|2010 PRODUCTS|PRACTICES|PERSPECTI
Page 3 and 4: Two views of the press room: on the
Page 5 and 6: Terminic gained second place in the
Page 7: Website: www.nacion.com Sheetfed Of
Page 11 and 12: Managing director René de Heij:
Page 13 and 14: Cutting-edge control technology mak
Page 15 and 16: Healthy expansion from half- to med
Page 17 and 18: The KBA LogoTronic production manag
Page 19 and 20: World makeready champion now at Rot
Page 21 and 22: “ We wanted to be one of the firs
Page 23 and 24: Classic packaging configuration: si
Page 25 and 26: Antistatic nozzles and heads Antist
Page 27 and 28: the fount solution in a moment’s
Page 29 and 30: Editora Abril in Sao Paulo Compacta
Page 31 and 32: The webs of the two presses can be
Page 33 and 34: EasyTronic control software support
Page 35 and 36: Koenig & Bauer ships further Comet
Page 37 and 38: plate loading and mounting. The sys
Page 39 and 40: On 14 December 2008 the first of se
Page 41 and 42: Websites: www.onlineprinters.com |
Page 43 and 44: Mousepads Display wobblers Flexible
Page 45 and 46: Second Rapida 75 for Länggass Druc
Page 47 and 48: Longstanding KBA customer Oceano in
Page 49 and 50: KBA users among winners of Druck&Me
Page 51 and 52: Print Week Awards 2009: KBA custome

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